Battery separators with improved conductance, improved batteries, systems, and related methods

Abstract

In accordance with at least selected embodiments, the present disclosure or invention is directed to improved battery separators, high conductance separators, improved lead-acid batteries, such as flooded lead-acid batteries, high conductance batteries, improved systems, and/or, improved vehicles including such batteries, and/or methods of manufacture or use of such separators or batteries, and/or combinations thereof. In accordance with at least certain embodiments, the present disclosure or invention is directed to improved lead acid batteries incorporating the improved separators and which exhibit increased conductance. Particular, non-limiting examples may include lead acid battery separators having structure or features designed to improve conductance, lower ER, lower water loss, and the like.

What is claimed is: 
     
       1. A lead acid battery comprising: polyolefin microporous membrane comprising polyethylene; a particle-like filler;
 a processing plasticizer;
 wherein the particle-like filler to polyethylene weight ratio is present in an amount from 1.5:1 to 6:1; 
 an optimized profile with a rib surface area, compared with a rib surface area of a conventional rib profile such as a solid vertical rib profile, that is 10-90% of said conventional rib surface area, preferably 30-70% of said conventional rib surface area, and more preferably, in some instances, 40-60% of said conventional rib surface area; 
 
 said microporous membrane having a shelf life estimated cold cranking amps loss as compared to an initial value of less than approximately 9%;
 and optionally, wherein the microporous membrane is characterized by one or more of the following: 
 a mean pore size of at least approximately 120 nm; 
 a diffusion coefficient of at least approximately 1.6.10-10 at −5° C., and an electrical resistance of approximately 40 mΩ·cm2 or lower; or 
 a diffusion coefficient of at least approximately 8.8.10-10 at 30° C., and an electrical resistance of approximately 40 mΩ·cm2 or lower. 
 
 
     
     
       2. The lead acid battery according to  claim 1 , wherein said shelf life estimated cold cranking amps loss as compared to an initial value of less than approximately 8%. 
     
     
       3. The lead acid battery according to  claim 1 , wherein said shelf life estimated cold cranking amps loss as compared to an initial value of less than approximately 7%. 
     
     
       4. The lead acid battery according to  claim 1 , wherein said filler is selected from the group consisting of silica, precipitated silica, fumed silica, and precipitated amorphous silica. 
     
     
       5. The lead acid battery according to  claim 1 , wherein said optimized profile is characterized by one from the group consisting of:
 ribbing, serrated ribbing, embossed ribbing and/or negative cross ribs and combinations thereof. 
 
     
     
       6. The lead acid battery according to  claim 1 , wherein said shelf life estimated cold cranking amps is measured at greater than approximately 30 days of resting at standard conditions. 
     
     
       7. The lead acid battery according to  claim 1 , wherein said battery is selected from the group consisting of: a flat-plate battery, a flooded lead acid battery, an enhanced flooded lead acid battery, a deep-cycle battery, an absorptive glass mat battery, a tubular battery, an inverter battery, a vehicle battery, a SLI battery, an ISS battery, an automobile battery, a truck battery, a motorcycle battery, an all-terrain vehicle battery, a forklift battery, a golf cart battery, a hybrid-electric vehicle battery, an electric vehicle battery, an e-rickshaw battery, an e-trike battery, and an e-bike battery. 
     
     
       8. A vehicle comprising a lead acid battery according to  claim 7 , wherein said vehicle comprises one from the group consisting of: an automobile, a truck, a motorcycle, an all-terrain vehicle, a forklift, a golf cart, a hybrid-electric vehicle, an electric vehicle, an e-rickshaw, an e-trike, and an e-bike.